Handrail system, kit and method

ABSTRACT

A composite handrail system comprising a plurality of upright posts; a plurality of composite rails extending between the adjacent upright posts at two points on the adjacent upright posts, the composite rails each having an internal reinforcing element, friction fit into a composite channel extending longitudinally inside said composite rail, and a composite cover friction fit over said composite channel. A plurality of composite sleeve-spindles extending between the composite rails and a plurality of connectors coupling the composite rails to the composite sleeve-spindles. The connectors being adapted to be mounted to the composite rails and adapted to receive and friction fit the composite sleeve-spindles.

FIELD OF THE INVENTION

[0001] The present invention relates generally to a handrail and morespecifically to a composite handrail assembly comprising a novelconnector and covering, and a kit comprising the handrail system.

BACKGROUND OF THE INVENTION

[0002] Deck systems are used both commercially and residentially andoften require a handrail to ensure maximum safety to the users. Ahandrail helps ensure that the people using the deck do not fall off.Furthermore a handrail is also important for any stairway attached tothe deck to ensure the safety of the users as they go up and down thestairs to the deck.

[0003] Traditionally decks and associated handrails have beenmanufactured from solid wood or some form of wood product. As such thedecks and handrails have been susceptible to damage from the elementssuch as rain, snow and wind. Therefore the production of the deck andhandrail from an alternative more sturdy material has been desirable.The industry has therefore turned to plastic to address some of theseproblems, although plastic has restrictions with respect to the amountof weight it can carry and its strength.

[0004] A number of different patents and inventions have tried toaddress the issue of strong decking and railing with improved durabilityfor the outdoors. For example U.S. Pat. No. 6,017,019 issued on Jan. 25,2000 to Erwin. This patent relates to a modular railing including aplurality of upright posts and a plurality of composite handrailsextending between adjacent ones of the upright posts. The compositehandrails each include a plastic outer shell and an internal metalreinforcing element extending longitudinally within the plastic shell.

[0005] DeSouza is the owner of U.S. Pat. No. 5,572,845, which issued onNov. 12, 1996. This patent relates to a wood railing assembly for usebetween vertical posts, which may be attached to a wood deck, utilizestop and bottom rails together with a middle rail.

[0006] Savenok is the owner of U.S. Pat. No. 5,957,437, which issued onSep. 28, 1999 and relates to a balustrade connecting structure. Theconnecting structure is used to connect the rail to a support structureand is constructed to be recessed into an end of a rail to enable theconnection of the rail to the support structure.

[0007] Forshee is the owner of U.S. Pat. No. 4,885,882 which issued onDec. 12, 1989. This patent relates to a cover for a wooden deckstructure which protects people walking on the deck structure fromsplinters. In one embodiment, the cover is in the form of a thin walled,U-shaped channel member which fits over one board of the deck structure.In doing so, the central section of the channel member overlies the topof the board while the sides of the channel member extend downwardlyalong the sides of the boards.

[0008] Oliveri et al. is the owner of U.S. Pat. No. 5,794,390, whichissued on Aug. 18, 1998. This patent relates to a structural coveringthat is attachable to a rail of a railing that has a top, a pair ofsides, ends, and a bottom, and that is attachable to a floor board of adeck that has a top, a pair of sides, ends and a bottom, while coveringmost of the rail of the railing and any exposed ends thereof andcovering most of the floor board of the deck and any exposed endsthereof so as to prevent splinters, hide knots, splintered wood,discolored wood, and cracks in the wood, and give a uniform look thatwill not rot.

[0009] Sorrentino is the owner of U.S. Pat. No. 4,269,532 which issuedon May 26, 1981. This patent relates to a coupling for joining tubingtogether in the manufacture of furniture and the like comprising a pairof sleeves mounted one on the other in coplanar relation with their axesat right angle to each other and a wall mounted at the inner end of oneof the sleeves with an opening in the wall for receiving a screw and thelike for fastening the tubing that extends through the other sleeve.

[0010] Although the above noted prior art addresses some of the problemsassociated with decks and associated handrails the prior art does notprovide for a handrail system and kit having that can be easilyassembled, while completely covering or hiding the fasteners resultingin a finished, clean professional look. Furthermore, the handrail systemmay be installed on an angle for stairs that mount the deck, or straighton the deck itself. Finally the handrail system has composite elementswhich allows for easy installation as well as improved strength whilemaintaining the look and feel of a wooden deck.

SUMMARY OF THE INVENTION

[0011] In accordance with one aspect of the present invention there isprovided an improved composite handrail system consisting of a pluralityof upright posts and a plurality of composite rails extending betweenadjacent upright posts at two points on the adjacent upright posts. Thecomposite rails may each have an internal reinforcing element which maybe friction fit into a composite channel extending longitudinally insideeach composite rail. A composite cover may be friction fit over thecomposite channel. A plurality of composite sleeve-spindles may extendbetween the composite rails. A plurality of connectors may couple thecomposite rails to the composite sleeve-spindles. The connectors may beadapted to mount to the composite rails and adapted to receive andfriction fit the composite sleeve-spindles.

[0012] Conveniently the internal reinforcing element may be a woodmember and the composite channel may be adapted to encase the woodmember to provide a consistent profile for the composite rail.Preferably the connectors may be hollow and have an outer wall and aninner wall, and a plurality of covered channels extending the length ofthe inner wall of the connectors. The covered channels may be adapted toreceive a series of fasteners for mounting the connectors to thecomposite rails.

[0013] Advantages of the present invention are that the handrail systemmay be installed on an angle or straight; once assembled all fastenersare completely hidden; the composite handrail system has the strength ofwood and looks like wood; the composite rails allow for the improvedstrength of the handrail system; allows for inconsistencies in the woodmember; easier installation; improved finish; easier assembling andfastening; friction fit of elements; connector allows for easy placementon the rails, a snug fit without rotation, and easy installation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] A detailed description of the preferred embodiments are providedherein below by way of example only and with reference to the followingdrawings in which:

[0015]FIG. 1, in a top perspective view, illustrates the handrail systemin accordance with the first preferred embodiment of the presentinvention.

[0016]FIG. 2, in front plan view, illustrates the handrail system ofFIG. 1.

[0017]FIG. 3, in an exploded view, illustrates the handrail system andthe handrail system kit of the fourth preferred embodiment of thepresent invention.

[0018]FIG. 4, in a side cross-section view, illustrates the compositerail of the second preferred embodiment and connector of the thirdpreferred embodiment of the present invention in operation.

[0019]FIG. 5, in a top cross-sectional view, illustrates the connector.

[0020] In the drawings, preferred embodiments of the invention areillustrated by way of example. It is to be expressly understood that thedescription and the drawings are only for the purpose of illustrationand as an aid to the understanding and are not intended as a definitionof the limits of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Referring to FIGS. 1, 2, and 3, there is illustrated inperspective and exploded views, a handrail system 10 in accordance witha preferred embodiment of the present invention. The handrail system 10includes a plurality of upright posts 12 and a plurality of compositerails 14 extending between adjacent upright posts 12 at two points 16and 18 on the adjacent upright posts 12. The composite rails 14 may eachhave an internal reinforcing element 20 which may be friction fit into acomposite channel 22 extending longitudinally inside each composite rail14.

[0022] A composite cover 24 may be friction fit over the compositechannel 22. A plurality of composite sleeve-spindles 26 may extendbetween the composite rails 14. A plurality of connectors 28 may couplethe composite rails 14 to the composite sleeve-spindles 26. Theconnectors 28 may be adapted to mount to the composite rails 14 andadapted to receive and friction fit the composite sleeve-spindles 26.

[0023] The internal reinforcing element 20 may be a wood member 30 thatmay be adapted to friction fit into the composite channel 22 providing asnug fit between the wood member 30 and the composite channel 22. Byencasing the wood member 30 in the composite channel 22, anyinconsistencies in the wood member 30 are overcome as the compositechannel 22 can flex around the wood member 30, and has sufficient spaceto completely encase the wood member 30. The composite cover 24 may be achannel cover 32 adapted to friction fit over the composite channel 22without requiring fasteners. The resulting composite rail 14 thereforeincludes the strength from the internal reinforcing element 20 or woodmember 30, while providing a clean profile from the friction fit of thechannel cover 32 over the composite channel 22 while doing away with theneed for fasteners. Finally the composite channel 22 and channel cover32 assembly allows for easier installation since it requires fewerparts.

[0024] Referring to FIGS. 4 and 5, the connectors 28 may be hollow andhave an outer wall 34 and an inner wall 36 and a plurality of coveredchannels 38 extending the length of the inner wall 36 of the connectors28. The covered channels 38 may be adapted to receive a series offasteners 40 for mounting the connectors 28 to the composite rails 14.The connectors 28 may be mounted not only flush or straight to thecomposite rails 14, but they may also be cut at an angle to allow forinstallation of the connectors 26 and the composite sleeve-spindles 26for stairs that mount the deck.

[0025] The connectors 26 may further comprise a series of ribs 42 on theouter wall 34 for the friction fit of the composite sleeve-spindles 26and to prevent rotation of the composite sleeve-spindles 26 on theconnectors 26. Furthermore the connectors 26 may be tapered on eitherend to allow for easy insertion into composite sleeve-spindles 26.

[0026] A kit for a handrail system is also disclosed which includes theconstituent parts described above which are adapted to be assembledtogether in connected relationship in differing handrail systemsproviding correspondingly different handrail system appearances andcharacteristics.

[0027] Referring to FIGS. 3 and 4, in operation, the handrail system'smethod of assembly includes the following steps. The user may firstposition a pair of upright posts 12 apart from one another in thedesired position. A first composite rail 50 is positioned between theadjacent upright posts 12 at a first point 16 to the adjacent uprightposts 12. The composite rail 50 may have an internal reinforcing element20 which is friction fit into a composite channel 22 that extendslongitudinally inside the composite handrail 50.

[0028] The composite rail 50 may be secured to the upright posts 12 withfasteners 44. A composite cover 24 is friction fit over the compositechannel 22 of the composite rail 14 thereby covering the internalreinforcing element 20 and the fasteners 44. A plurality of connectors28 which are adapted to be mounted to the composite rails 50 areattached at desired points along the composite rail 50. The connectors28 are also adapted to receive and friction fit a plurality of compositesleeve-spindles 26, which have a first end 46 and a second end 48. Thefirst end 46 of composite sleeve-spindles 26 are friction fit into theconnectors 28.

[0029] A second composite rail 52 also having an internal reinforcingelement 20 is friction fit into a composite channel 22 extendinglongitudinally inside the composite rail 52 extending between theadjacent upright posts 12 at a second point 18 on the adjacent uprightposts 12. A second plurality of connectors 28 is attached to the secondcomposite rail 52 at desired points. The second plurality of connectors28 are then friction fit to the second end 48 of the compositesleeve-spindles 26, therefore resulting in the composite sleeve-spindles26 extending between the first and second composite rails 50 and 52.

[0030] The second composite rail 52 is secured to the upright posts 12with fasteners 44. A second composite cover 24 is friction fit over thecomposite channel 22 of the second composite rail 52 thereby coveringthe internal reinforcing element 20 and the fasteners 44.

[0031] Other variations and modifications of the invention are possible.All modifications or variations are believed to be within the sphere andscope of the invention as defined by the claims appended hereto.

I claim:
 1. A composite handrail system comprising: (a) a plurality ofupright posts; (b) a plurality of composite rails extending betweenadjacent upright posts at two points on said adjacent upright posts,said composite rails each having an internal reinforcing element,friction fit into a composite channel extending longitudinally insidesaid composite rail, and a composite cover friction fit over saidcomposite channel; (c) a plurality of composite sleeve-spindlesextending between said composite rails; and (d) a plurality ofconnectors coupling said composite rails to said compositesleeve-spindles, said connectors being adapted to be mounted to saidcomposite rails and adapted to receive and friction fit said compositesleeve-spindles.
 2. A composite handrail system as claimed in claim 1wherein said internal reinforcing element is wood member friction fitinto said composite channel.
 3. A composite handrail system as claimedin claim 2 wherein said composite channel is adapted to encase said woodmember and provide a consistent profile for said composite rail.
 4. Acomposite handrail system as claimed in claim 3 wherein said compositecover is a composite channel cover adapted to friction fit over saidcomposite channel without requiring fasteners.
 5. A composite handrailsystem as claimed in claim 4 wherein said connectors are hollow and havean outer wall and an inner wall.
 6. A composite handrail system asclaimed in claim 5 wherein said connectors further comprise a pluralityof covered channels extending the length of said inner wall of saidconnectors and are adapted to receive a series of fasteners for mountingsaid connectors to said composite rails.
 7. A composite handrail systemas claimed in claim 6 wherein said connectors further comprise a seriesof ribs on said outer wall for the friction fit of said composite sleevespindles and to prevent rotation of said composite sleeve spindles onsaid connectors.
 8. A composite handrail system as claimed in claim 7wherein said connectors are made from composite material.
 9. A compositerail for a handrail system for extending between adjacent upright postscomprising: (a) an internal reinforcing element friction fit into acomposite channel, extending longitudinally inside said compositehandrail, and (b) a composite cover friction fit over said compositechannel for a consistent profile of said composite rail.
 10. A compositerail for a handrail system as claimed in claim 9 wherein said internalreinforcing element is wood member friction fit into said compositechannel.
 11. A composite rail for handrail system as claimed in claim 10wherein said composite channel is adapted to encase said wood member andprovide a consistent profile for said composite rail.
 12. A compositerail for handrail system as claimed in claim 11 wherein said compositecover is a cover channel adapted to friction fit over said compositechannel without requiring fasteners.
 13. A connector for a compositehandrail system having a plurality of composite rails and compositesleeve-spindles comprising a member adapted to be mounted to saidcomposite rails and adapted to receive and friction fit said compositesleeve-spindles for coupling said composite rails to said compositesleeve-spindles.
 14. A connector as claimed in claim 13 wherein saidconnectors are hollow and have an outer wall and an inner wall.
 15. Aconnector as claimed in claim 14 wherein said connectors furthercomprise a plurality of covered channels extending the length of saidinner wall of said connectors and are adapted to receive a series offasteners for mounting said connectors to said composite rails.
 16. Aconnector claimed in claim 15 wherein said connectors further comprise aseries of ribs on said outer wall for the friction fit of said compositesleeve spindles and to prevent rotation of said composite sleevespindles on said connectors.
 17. A connector as claimed in claim 16wherein said connectors are made from composite material.
 18. A handrailsystem kit including constituent parts which are adapted to be assembledtogether in connected relationship in differing handrail systemsproviding correspondingly different handrail system appearances andcharacteristics, comprising: (a) a plurality of upright posts; (b) aplurality of composite rails extending between adjacent upright posts attwo points on said adjacent upright posts, said composite rails eachhaving an internal reinforcing element, friction fit into a compositechannel extending longitudinally inside said composite rail, and acomposite cover friction fit over said composite channel; (c) aplurality of composite sleeve-spindles extending between said compositerails; and (d) a plurality of connectors coupling said composite railsto said composite sleeve-spindles, said connectors being adapted to bemounted to said composite rails and adapted to receive and friction fitsaid composite sleeve-spindles.
 19. A handrail system kit as claimed inclaim 18 wherein said internal reinforcing element is wood memberfriction fit into said composite channel.
 20. A method of assembling asection of a handrail system comprising the steps of: (a) positioning apair of upright posts; (b) extending between said adjacent upright postsat a first point on said adjacent upright posts, a first composite railhaving an internal reinforcing element friction fit into a compositechannel extending longitudinally inside said composite handrail; (c)securing said composite rail to said upright posts with fasteners; (d)friction fitting a composite cover over said composite channel of saidcomposite rail thereby covering said internal reinforcing element andsaid fasteners; (e) mounting a plurality of connectors being adapted tobe mounted to said composite rails and adapted to receive and frictionfit a plurality of composite sleeve-spindles having a first end and asecond end, at desired points on said composite rail; (f) friction fitsaid first end of said composite sleeve-spindles into said connectors;(g) extending between said adjacent upright posts at a second point onsaid adjacent upright posts, a second composite rail having an internalreinforcing element friction fit into a composite channel extendinglongitudinally inside said composite rail; (h) mounting said secondplurality of connectors to said second composite rail at desired points;(i) friction fitting a second plurality of connectors to said second endof said composite sleeve-spindles, said composite sleeve-spindlesextending between said first and second composite rails; (j) securingsaid second composite rail to said upright posts with fasteners; (k)friction fitting a second composite cover over said composite channel ofsaid second composite rail thereby covering said internal reinforcingelement and said fasteners.